Connector Terminal Geometry for Error-Proof Mold Placement

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Solution Overview

Problem

Existing connectors face challenges in accurately arranging two types of terminals with different thicknesses, leading to potential errors in the molding process.

Innovation Solution

The connector design includes specific terminal configurations, such as the first terminal with a connecting portion, an intermediate portion, and an exposed portion, and the second terminal with a connecting portion, which are shaped to correspond to the mold holes, preventing incorrect insertion and ensuring accurate positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the first terminal is made thinner to fit in the mold, then it can be inserted into the second terminal arrangement hole, but arrangement errors occur since the first and second terminals are similar in shape

Engineering Contradiction:
ImproveInsertability of terminal into moldVSAvoidArrangement accuracy of terminals
Core Design Contradiction:
Ease of operationVSManufacturing precision

Solution Approach 1:

The patent applies asymmetry by making the first terminal have a non-linear extension shape with varying thickness, while the second terminal has a linear extension shape. This asymmetric design ensures that each terminal has a unique geometry that corresponds to its specific arrangement hole, preventing the first terminal from being mistakenly inserted into the second terminal's arrangement hole. The different shapes create inherent directional guidance and positioning features that eliminate arrangement errors during the molding process.

Inventive Principle:
Principle #4Asymmetry

2Ease of manufacture

If the first terminal has uniform thickness, then it is easier to manufacture, but it cannot be distinguished from the second terminal for proper arrangement

Engineering Contradiction:
ImproveManufacturing simplicity of terminalVSAvoidPositioning accuracy of terminal
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating a thickness variation in a specific region of the first terminal. The first terminal has a first region with a first thickness and a second region with a second thickness that is different from the first thickness. This localized thickness change provides a distinctive geometric feature that enables differentiation from the second terminal during arrangement, while the majority of the terminal structure can still be manufactured with standard uniform dimensions, maintaining ease of manufacture.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20250087923A1connector
Publication Date: 2025.03.13 SUMITOMO WIRING SYSTEMS LTD
  • US20250087923A1 patent drawing
  • US20250087923A1 patent drawing
  • US20250087923A1 patent drawing

AI summary

A first terminal includes a first connecting portion including a contact point with a first mating terminal, the first connecting portion being an end region including a first end in the first terminal, and a first intermediate portion adjacent to the first connecting portion in an extension direction of the first terminal. A second terminal includes a second connecting portion including a contact point with a second mating terminal, the second connecting portion being an end region including a second end in the second terminal. The first connecting portion and the second connecting portion are entirely exposed from a housing. The first intermediate portion includes a first exposed portion exposed from the housing, the first exposed portion being an end region adjacent to the first connecting portion in the first intermediate portion, and a first embedded portion embedded in the housing.